Mounting arrangement for a heat exchanger

ABSTRACT

A mounting arrangement for a motor vehicle, at least having at least one heat exchanger and a protective element for the at least one heat exchanger, which with a grid structure through which a fluid may flow at least partially covers a surface, over which the fluid may flow, of the at least one heat exchanger, wherein the protective element is a component that is manufactured by an injection molding process, and has at least one sealing element, integrally formed on the protective element in a multicomponent method, for conducting flow of the fluid.

FIELD OF THE INVENTION

The invention relates to a mounting arrangement for at least one heatexchanger for a motor vehicle.

BACKGROUND OF THE INVENTION

For conducting a heat exchanger fluid, a heat exchanger may include afirst header box and a second header box, and also at least a pluralityof pipes, each extending from the first header box toward the secondheader box. The pipes may be situated spaced apart from one another,between the first and second header boxes, in such a way that they havea surface over which a fluid (ambient air, for example) may flow along alongitudinal axis of the motor vehicle. Heat exchange takes placebetween the heat exchanger fluid, conducted through the pipes, and thefluid that flows across the pipes along an axial direction. Inparticular, the heat exchanger in conjunction with a fan guard issituated in the front end of a motor vehicle, it being common to installthe heat exchanger in front of a drive unit of the motor vehicle and infront of the fan guard in the travel direction.

In these types of mounting arrangements, gaps between the individualcomponents, for example the heat exchanger and the fan guard, should besealed off from the surroundings, so that predefined flow paths of theambient air, for example (when the motor vehicle is traveling), aremaintained, and the efficiency of the heat exchanger is thusmaximizable.

Cooling systems are becoming more complex due to the increasingtechnical demands, while at the same time, predefined states must beachieved in a more precise manner (the sealing design, for example).

Protective grids are known from DE 101 31 321 B4, FR 3 035 956 A1, andUS 2018/0120040 A1, which are situated in front of the heat exchangerwith respect to the travel direction of the motor vehicle. Theprotective grids are intended to prevent damage to the heat exchanger,for example from road stones.

The object of the present invention is to at least partially solve theproblems stated with regard to the prior art. In particular, the aim isto keep the level of complexity of a mounting arrangement low, andpreferably also to meet the increasing demands with regard to sealingand cooling power.

SUMMARY OF THE INVENTION

These objects are achieved by a mounting arrangement having the featuresaccording to the independent claims. Advantageous refinements are thesubject matter of the dependent claims. The features individually setforth in the claims may be combined with one another in atechnologically meaningful manner, and may be supplemented by theexplanatory material from the description and/or details from thefigures, which indicate further embodiment variants of the invention.

A mounting arrangement for a motor vehicle is proposed, at least havingat least one heat exchanger (see the above statements concerning heatexchangers; the heat exchanger is in particular an air intercooler or acondenser), and a protective element for the at least one heatexchanger, which with a grid structure through which a fluid may flow atleast partially covers a surface, over which the fluid may flow, of theat least one heat exchanger. The protective element is a component thatis manufactured by an injection molding process (injection-moldedcomponent), and has at least one sealing element, integrally formed onthe protective element in a multicomponent method, for conducting flowof the fluid.

The motor vehicle has a longitudinal axis (extending transversely withrespect to the wheel axles), a transverse axis (extending transverselywith respect to the longitudinal axis), and a yaw axis (transverse tothe longitudinal axis and transverse axis, generally parallel to theforce of gravity). In the following discussion, it is assumed that theat least one heat exchanger is situated in the motor vehicle essentiallyin a plane spanned by the transverse axis and the yaw axis. In addition,it is assumed that a fluid flows through the heat exchanger along anaxial direction (due to the motion of the motor vehicle in the traveldirection, ambient air flows essentially along the longitudinal axis).Therefore, the axial direction used in the following discussion isessentially parallel to the longitudinal axis. The radial direction andthe circumferential direction used in the following discussion in eachcase extend transversely with respect to the axial direction, and thusessentially transversely with respect to the longitudinal axis. The term“axis” and the indicated directions are also used below for the mountingarrangement, assuming the mentioned orientation of the mountingarrangement or of the at least one heat exchanger. If the mountingarrangement or the at least one heat exchanger is oriented differentlyin the motor vehicle, correspondingly differently oriented axes ordirections then apply for the following statements.

The mounting arrangement is situated in particular in a front area (withrespect to the customary travel direction) of the motor vehicle (in theso-called front end). The mounting arrangement is in particularinstalled in front of a drive unit of the motor vehicle in the traveldirection.

The mounting arrangement may be connected to the motor vehicle via oneof the components of the mounting arrangement described below, and/orvia a separate mounting support.

Injection molding is a shaping process used in plastic processing, forexample. The material in question is liquefied (plasticized) with aninjection molding machine, and injected under pressure into a mold, theinjection mold. In the mold, the material goes into the solid state viacooling or a crosslinking reaction, and may be removed after the mold isopened. The hollow space, the cavity, of the mold determines the shapeand the surface structure of the finished part. Within the scope of theinjection molding process, a multicomponent method may also be carriedout. In the method, several different materials (components) aresupplied to the mold, so that different areas of a workpiece may be madeof respectively different materials, although the workpiece as a wholeis manufacturable in one piece. The result is a multicomponentinjection-molded component, wherein the two components are presentphysically separate from one another and are directly joined together,in one part or one piece, and/or are not nondestructively separable fromone another.

The grid structure extends in particular at least over a lower portionof the heat exchanger with respect to the force of gravity. Inparticular, the grid structure extends over a majority of or over theentire width (transverse to the longitudinal axis) of the heatexchanger. In particular, the grid structure should on the one handprotect the heat exchanger or the pipes of the heat exchanger frommechanical stress, for example from road stones. On the other hand, thegrid structure should have the lowest possible flow resistance withrespect to the fluid. In particular, the grid structure extends over atleast 30%, preferably over at least 50%, of the surface area of thepipes of the heat exchanger pointing in the travel direction.

In the present case, it is proposed in particular to manufacture theprotective element using a two-component method, wherein the at leastone sealing element is made of a first material, and at least the gridstructure is made of a different, second material.

In particular, it is possible for the grid structure to be manufacturedfrom a material that is provided for the intended purpose, i.e., inparticular having sufficient resistance to road stones and low elasticdeformability. In contrast, in particular the at least one sealingelement has a lower density and/or a smaller wall thickness (lessdemands on the strength, and therefore an advantageous more lightweightdesign) and/or greater elastic deformability (better deformation andthus more flexible adaptation to contact surfaces of adjacent componentsfor forming a seal of a flow path of the fluid with respect to thesurroundings of the mounting arrangement).

In particular, the at least one sealing element of the protectiveelement has a lower modulus of elasticity than at least the gridstructure of the protective element. For linear elastic behavior, themodulus of elasticity describes the proportional relationship betweentension and elongation during the deformation of a solid body.

In particular the protective element, in particular at least the gridstructure and/or the at least one sealing element, are/is at leastpartially manufactured from one or more different plastics (polymers,optionally fiber-reinforced). In particular, the grid structure is (atleast partially) made of known PA66-GF30, a polyamide. In particular,the at least one sealing element is made of known TPV-(EPDM and PP) orfrom known TPS-SBS.

The protective element preferably has a frame part between the at leastone sealing element and the grid structure. In particular, the gridstructure and the at least one sealing element are joined together inone piece via the frame part.

In particular, the protective element and the at least one heatexchanger are (directly) connected to one another at least via at leastone first mounting situated on the frame part. In particular, the firstmounting comprises a clip connection, a screw connection, a clampconnection, a rivet connection, an adhesive connection, or the like.

In particular, the protective element and the at least one heatexchanger are aligned with one another via at least one centeringdevice, for example a centering pin.

In particular, the frame part and the grid structure are made of thesame material.

In particular, the frame part forms a frame having a design that isclosed all around in a circumferential direction.

The at least one sealing element preferably extends at least partiallyalong the frame part, closed all around, along the circumferentialdirection. In particular, the at least one sealing element may haveopenings or slots, so that a desired pattern may be ensured in cornerareas of the protective element without undesirable deformation of thesealing element.

Alternatively or additionally, a plurality of sealing elements may beprovided which are spaced apart from one another on the frame part alongthe circumferential direction.

In particular, the at least one sealing element, starting from the framepart, extends outwardly at least in a radial direction.

Alternatively or additionally, the at least one sealing element,starting from the frame part, may extend inwardly at least in a radialdirection.

In addition, the sealing element may extend, additionally orexclusively, at least partially along the axial direction.

In particular, the mounting arrangement additionally has at least oneseal carrier and a fan guard, wherein the seal carrier seals off withrespect to the surroundings a flow path for the fluid, extending alongan axial direction, between the heat exchanger and the fan guard.

A fan guard is used to accommodate at least one fan wheel via which afluid flow may be forced through the heat exchanger, in particular alsowhen the motor vehicle is at a standstill.

In particular, the aim is to seal off a flow path of a fluid withrespect to the surroundings of the mounting arrangement in the mosteffective manner possible, so that a fluid can flow only across the heatexchanger and through the fan of the fan guard.

In particular, the seal carrier is connected to the protective elementvia at least one second mounting. In particular, the second mountingcomprises a clip connection, a screw connection, a clamp connection, arivet connection, an adhesive connection, or the like.

In particular, the seal carrier and the at least one heat exchanger arealigned with one another via at least one centering device, for examplea centering pin.

In particular, the seal carrier is connected to the at least one heatexchanger via at least one third mounting. In particular, the thirdmounting comprises a clip connection, a screw connection, a clampconnection, a rivet connection, an adhesive connection, or the like.

In particular, the seal carrier and the protective element are alignedwith one another via at least one centering device, for example acentering pin.

In particular, the fan guard is connected to the at least one heatexchanger via at least one fourth mounting. In particular, the fourthmounting comprises a clip connection, a screw connection, a clampconnection, a rivet connection, an adhesive connection, or the like.

In particular, the fan guard and the at least one heat exchanger arealigned with one another via at least one centering device, for examplea centering pin.

A motor vehicle having a drive unit (for example, an electric machine,an internal combustion engine, or the like) for driving the motorvehicle, and the described mounting arrangement are proposed. Themounting arrangement is situated in particular in a front area (withrespect to the customary travel direction) of the motor vehicle (frontend). The mounting arrangement is in particular installed in front of adrive unit of the motor vehicle, in the travel direction.

Due to the design of the protective element or the mounting arrangement,a fluid or cooling air utilization level may be increased by up to 12%,depending on the motor vehicle. In addition, recirculation of warm fluidor warm ambient air in front of the at least one heat exchanger may beat least improved by the fan operation when the motor vehicle is instandstill or idling mode.

The statements concerning the mounting arrangement may be applied inparticular to the motor vehicle, and vice versa.

As a precaution, it is noted that the ordinal numbers used herein(“first,” “second,” “third,” . . . ) are used primarily (only) todistinguish between multiple similar objects, variables, or processes;i.e., in particular no dependency and/or sequence of these objects,variables, or processes relative to one another are/is necessarilyspecified. If a dependency and/or sequence is necessary, this isexplicitly indicated herein, or is readily apparent to those skilled inthe study of the embodiment specifically described. If a component maybe present in a plurality (“at least one”), the description for one ofthese components may similarly apply for all or a portion of theplurality of these components, although this is not absolutelynecessary.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention and the technical context are explained in greater detailbelow with reference to the appended figures. It is pointed out that theinvention is not to be construed as being limited by the illustratedexemplary embodiments. In particular, unless explicitly statedotherwise, it is also possible to extract partial aspects of theinformation shown in the figures and combine them with other componentsand findings from the present description. In particular, it is notedthat the figures and in particular the illustrated proportions are onlyschematic. In the figures:

FIG. 1: shows a motor vehicle in a side view;

FIG. 2: shows a protective element in a perspective view;

FIG. 3: shows a mounting arrangement in an exploded illustration in aperspective view;

FIG. 4: shows the mounting arrangement according to FIG. 3 in a firstperspective view;

FIG. 5: shows the mounting arrangement according to FIGS. 3 and 4 in asecond perspective view;

FIG. 6: shows a first detail of the mounting arrangement according toFIGS. 3 through 5 in a perspective view; and

FIG. 7: shows a second detail of the mounting arrangement according toFIGS. 3 through 5 in a perspective view.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 shows a motor vehicle 2 in a side view. In the front end, themotor vehicle 2 has a mounting arrangement 1 and a drive unit 17 insuccession. The motor vehicle 2 has a longitudinal axis 22, a transverseaxis 23, and a yaw axis 24.

A fluid 5 flows through the motor vehicle 2 along the flow path 15 (whenthe motor vehicle 2 is moving in the travel direction), parallel to thelongitudinal axis 14. The fluid 5 acts on and flows across or throughthe heat exchanger 3 of the mounting arrangement 1. A protective element4 of the mounting arrangement 1 protects the heat exchanger 3 fromdamage from stones 25, which may be tossed up when the motor vehicle 2is traveling along the roadway 26.

FIG. 2 shows a protective element 4 in a perspective view. Theprotective element 4 has a grid structure 6 through which a fluid 5 mayflow, and which at least partially covers a surface of the heatexchanger 3 across which the fluid 5 may flow. The protective element 4is a component that is manufactured by an injection molding process, andhas a sealing element 8, integrally formed onto the protective element 4in a multicomponent method, for conducting flow of the fluid 5.

The grid structure 6 extends over a lower portion of the heat exchanger3 opposite the force of gravity (extending along the yaw axis 24; seeFIG. 1). The grid structure 6 extends over the entire width (transverseto the longitudinal axis 22) of the heat exchanger 3. The protectiveelement 4 has a frame part 9 between the sealing element 8 and the gridstructure 6. The grid structure 6 and the sealing element 8 are joinedtogether in one piece via the frame part 9. The frame part 9 forms aframe having a design that is closed all the way around in acircumferential direction 10. The sealing element 8, starting from theframe part 9, extends outwardly at least in a radial direction 11.

FIG. 3 shows a mounting arrangement 1 in an exploded illustration in aperspective view. FIG. 4 shows the mounting arrangement 1 according toFIG. 3 in a first perspective view. FIG. 5 shows the mountingarrangement 1 according to FIGS. 3 and 4 in a second perspective view.FIG. 6 shows a first detail of the mounting arrangement 1 according toFIGS. 3 through 5 in a perspective view. FIG. 7 shows a second detail ofthe mounting arrangement 1 according to FIGS. 3 through 5 in aperspective view. FIGS. 3 through 7 are described together in thefollowing discussion, with reference to the statements for FIGS. 1 and2.

Along the flow path 15 of a fluid 5, the mounting arrangement 1 has insuccession a protective element 4, a heat exchanger 3, a seal carrier12, and a fan guard 13, which are connected or connectable to oneanother to form an assembly or mounting unit.

The protective element 4 and the heat exchanger 3 are (directly)connected to one another via first mountings 18 situated on the framepart 9 (see FIGS. 3, 6, and 7).

The sealing element 8 extends at least partially along the frame part 9,closed all around, along the circumferential direction 10. The sealingelement 8 has slots, so that a desired pattern may be ensured in cornerareas of the protective element 4 without undesirable deformation of thesealing element 8 having a circumferentially closed design.

The seal carrier 12 seals off with respect to the surroundings 16 a flowpath 15 for the fluid 5, extending along an axial direction 14, betweenthe heat exchanger 3 and the fan guard 13.

The fan guard 13 is used here to accommodate a fan wheel, via which afluid flow may be forced through the heat exchanger 3, in particularwhen the motor vehicle 3 is at a standstill.

The seal carrier 12 is connected to the protective element 4 via aplurality of second mountings 19 (see FIGS. 3, 4, and 5).

The seal carrier 12 is also connected to the heat exchanger 3 via aplurality of third mountings 20 (see FIGS. 3 and 5).

The fan guard 13 is connected to the heat exchanger 3 via a plurality offourth mountings 21 (see FIGS. 3, 4, 5, and 7).

LIST OF REFERENCE NUMERALS

-   -   1 mounting arrangement    -   2 motor vehicle    -   3 heat exchanger    -   4 protective element    -   5 fluid    -   6 grid structure    -   7 surface    -   8 sealing element    -   9 frame part    -   10 circumferential direction    -   11 radial direction    -   12 seal carrier    -   13 fan guard    -   14 axial direction    -   15 flow path    -   16 surroundings    -   17 drive unit    -   18 first mounting    -   19 second mounting    -   20 third mounting    -   21 fourth mounting    -   22 longitudinal axis    -   23 transverse axis    -   24 yaw axis    -   25 stone    -   26 roadway

1. A mounting arrangement for a motor vehicle, comprising: at least oneheat exchanger, and a protective element for the at least one heatexchanger, having a grid structure through which a fluid may flow thatat least partially covers a surface, over which the fluid may flow, ofthe at least one heat exchanger, wherein the protective element is acomponent that is manufactured by an injection molding process, and hasat least one sealing element, integrally formed on the protectiveelement in a multicomponent method, for conducting flow of the fluid. 2.The mounting arrangement according to claim 1, wherein the at least onesealing element of the protective element has at least a lower density,a smaller wall thickness, or greater elastic deformability than at leastthe grid structure of the protective element.
 3. The mountingarrangement according to claim 1, wherein the protective element has aframe part between the at least one sealing element and the gridstructure.
 4. The mounting arrangement according to claim 3, wherein theprotective element and the at least one heat exchanger (are connected toone another at least via at least one first mounting situated on theframe part.
 5. The mounting arrangement according to claim 3, whereinthe frame part and the grid structure are made of the same material. 6.The mounting arrangement according to claim 3, wherein the frame partforms a frame having a design that is closed all around in acircumferential direction.
 7. The mounting arrangement according toclaim 6, wherein the at least one sealing element extends at leastpartially along the frame part, closed all around, along thecircumferential direction.
 8. The mounting arrangement according toclaim 1, wherein the at least one sealing element, starting from theframe part, extends outwardly at least in a radial direction.
 9. Themounting arrangement according to claim 1, wherein the mountingarrangement additionally has at least one seal carrier and a fan guard,wherein the seal carrier seals off with respect to the surroundings aflow path for the fluid, extending along an axial direction, between theat least one heat exchanger and the fan guard.
 10. The mountingarrangement according to claim 9, wherein the seal carrier is connectedto the protective element via at least one second mounting.
 11. Themounting arrangement according to one of preceding claims 9 and 10,wherein the seal carrier (12) is connected to the at least one heatexchanger (3) via at least one third mounting (20).
 12. The mountingarrangement (1) according to claim 9, wherein the fan guard is connectedto the at least one heat exchanger via at least one fourth mounting. 13.A motor vehicle having a drive unit for driving the motor vehicle and amounting arrangement according to claim 1.